SECTION 6 MAINTENANCE STANDARD

Group 1 Operational Performance Test ----------------------------------------------------------------------- 6-1

Group 2 Major Components ------------------------------------------------------------------------------------------ 6-21
Group 3 Track and Work Equipment ---------------------------------------------------------------------------- 6-30
 SECTION 6 MAINTENANCE STANDARD
GROUP 1 OPERATIONAL PERFORMANCE TEST

1. PURPOSE
Performance tests are used to check:
1) OPERATIONAL PERFORMANCE OF A
NEW MACHINE Working
condition
Whenever a new machine is delivered in
parts and reassembled at a customer's
site, it must be tested to confirm that the
operational performance of the machine
meets Hyundai spec. Maintenance
record
2) OPERATIONAL PERFORMANCE OF A
WORKING MACHINE
With the passage of time, the machine's
operational performance deteriorates, so
that the machine needs to be serviced
periodically to restore it to its original
Operating
performance level.
Before servicing the machine, conduct
performance tests to check the extent of
deterioration, and to decide what kind of
service needs to be done (by referring to
the "Service Limits" in this manual). 7077MS01

3) OPERATIONAL PERFORMANCE OF A
REPAIRED MACHINE
After the machine is repaired or serviced, it
must be tested to confir m that its
operational performance was restored by
the repair and/or service work done.

6-1
2. TERMINOLOGY
1) STANDARD
Specifications applied to the brand-new
machine, components and parts.

7077MS02

2) SERVICE LIMIT
The lowest acceptable performance level.
When the perfor mance level of the
machine falls below this level, the machine
must be removed from work and repaired.
Necessary parts and components must be
replaced.

7077MS03

6-2
3. OPERATION FOR PERFORMANCE
TESTS
1) Observe the following rules in order to
carry out performance tests accurately and
safely.
(1) The machine
Repair any defects and damage found,
such as oil or water leaks, loose bolts,
cracks and so on, before starting to test.
(2) Test area
೵ Select a hard, flat surface.
೶ Secure enough space to allow the
machine to run straight more than 20m,
and to make a full swing with the front
attachment extended.
೷ If required, rope off the test area and
provide signboards to keep unauthorized
personnel away.
(3) Precautions
೵ Before starting to test, agree upon the
signals to be employed for communication
among coworkers. Once the test is
7-3 (140-7)
started, be sure to communicate with
each other using these signals, and to
follow them without fail.
೶ Operate the machine carefully and
always give first priority to safety.
೷ While testing, always take care to avoid
accidents due to landslides or contact
with high voltage power lines. Always
confirm that there is sufficient space for
full swings.
೸ Avoid polluting the machine and the
ground with leaking oil. Use oil pans to
catch escaping oil. Pay special attention
to this when removing hydraulic pipings.
(4) Make precise measurements
೵ Accurately calibrate test instruments in
advance to obtain correct data.
೶ Carry out tests under the exact test
conditions prescribed for each test item.
೷ Repeat the same test and confirm that
the test data obtained can be procured
repeatedly. Use mean values of
measurements if necessary.

6-3
2) ENGINE SPEED
(1) Measure the engine speed at each power
mode
੔ The engine speed at each power mode CLUSTER
must meet standard RPM; if not, all other
operational performance data will be
unreliable. It is essential to perform this
test first.
(2) Preparation
೵ Warm up the machine, until the engine
coolant temperature reaches 50˚C or
more, and the hydraulic oil is 50਺5˚C.
೶ Set the accel dial at 10 (Max) position.
೷ Measure the engine RPM. Engine RPM display
Power mode switch
(3) Measurement Pilot lamp(S)
೵ Start the engine. The engine will run at
start idle speed. Measure engine speed
with a engine rpm display.
೶ Measure and record the engine speed at
each mode (P, S).
೷ Select the P-mode.
೸ Lightly operate the bucket control lever a
few times, then return the control lever to
neutral; The engine will automatically
enter the auto-idle speed after 4
seconds.
೹ Measure and record the auto deceleration
speed. 85A6MS01

(4) Evaluation
The measured speeds should meet the following specifications.
Unit : rpm
Model Engine speed Standard Remark
Start idle 1000਺50
P mode 2100਺50
HX85A
S mode 1950਺50
Auto decel 1100਺50
Condition : Set the accel dial at 10 (Max) position.

6-4
3) TRAVEL SPEED
(1) Measure the time required for the
excavator to travel a 20m test track.
(2) Preparation
೵ Adjust the tension of both tracks to be
equal.
೶ Prepare a flat and solid test track 20m in
length, with extra length of 3 to 5m on
both ends for machine acceleration and 0.3~0.5m
deceleration.
೷ Hold the bucket 0.3 to 0.5m above the
ground with the arm and bucket rolled in.
೸ Keep the hydraulic oil temperature at
85A6MC04
50਺5˚C.
(3) Measurement
೵ Measure both the low and high speeds
of the machine.
೶ Before starting either the low or high
speed tests, adjust the travel mode
switch to the speed to be tested.
೷ Star t traveling the machine in the
acceleration zone with the travel levers
at full stroke.
೸ Measure the time required to travel 20m. 3 ~ 5m 20m 3 ~ 5m
೹ After measuring the forward travel
speed, turn the upperstructure 180ਟ
and measure the reverse travel speed.
೺ Repeat steps ೸ and ೹ three times in
each direction and calculate the average
85A6MC05
values.
(4) Evaluation
The average measured time should meet the following specifications.
Unit : Seconds / 20m
Model Travel speed Standard Maximum allowable Remarks
1 Speed 26.0਺2.0 32.5
HX85A
2 Speed 13.6਺1.0 17

6-5
4) TRACK REVOLUTION SPEED
(1) Measure the track revolution cycle time
with the track raised off ground.
(2) Preparation
೵ Adjust the tension of both side tracks to
be equal.
೶ On the track to be measured, mark one
shoe with chalk.
೷ Swing the upperstructure 90˚ and lower
the bucket to raise the track off ground.
Keep the boom-arm angle between 90 to
110˚ as shown. Place blocks under
machine frame. 90 ~ 110
೸ Keep the hydraulic oil temperature at
50਺5˚C.
(3) Measurement
೵ Select the following switch positions. Mark
85A6MC06
ਠ Travel mode switch : 1 or 2 speed
೶ Operate the travel control lever of the
raised track in full forward and reverse.
೷ Rotate 1 turn, then measure time taken
for next 3 revolutions.
೸ Raise the other side of machine and
repeat the procedure.
೹ Repeat steps ೷ and ೸ three times and
calculate the average values.
(4) Evaluation
The revolution cycle time of each track should meet the following specifications.
Unit : Seconds / 3 revolutions
Model Travel speed Standard Maximum allowable
1 Speed 21.2਺1.5 26.3
HX85A (Rubber track)
2 Speed 10.9਺1.5 13.6

6-6
5) TRAVEL DEVIATION
(1) Measure the deviation by the tracks from
a 20m straight line.
(2) Preparation
೵ Adjust the tension of both tracks to be
equal.
೶ Provide a flat, solid test yard 20m in
length, with extra length of 3 to 5m on
0.3~0.5m
both ends for machine acceleration and
deceleration.
೷ Hold the bucket 0.3 to 0.5m above the
ground with the arm and bucket rolled in.
೸ Keep the hydraulic oil temperature at 85A6MC04

50਺5˚C.
(3) Measurement
೵ Measure the amount of mistracking at
high and low travel speeds.
೶ Star t traveling the machine in the
acceleration zone with the travel levers 3~5m extra length
a
at full stroke.

M
20
೷ Measure the distance between a straight
20m line and the track made by the
machine. (dimension a) 3~5m extra length
೸ After measuring the tracking in forward
travel, turn the upperstructure 180˚ and
measure that in reverse travel.
೹ Repeat steps ೷ and ೸ three times and 7-7(2) 140-7

calculate the average values.

(4) Evaluation
Mistrack should be within the following specifications.
Unit : mm / 20m
Model Standard Maximum allowable Remarks
HX85A 200 below 240

6-7
6) SWING SPEED
(1) Measure the time required to swing three
complete turns.
(2) Preparation
೵ Check the lubrication of the swing gear
and swing bearing.
೶ Place the machine on flat, solid ground
with ample space for swinging. Do not
conduct this test on slopes.
೷ With the arm rolled out and bucket rolled
in, hold the bucket so that the height of
the bucket pin is the same as the boom
foot pin. The bucket must be empty.
೸ Keep the hydraulic oil temperature at
50਺5˚C. 85A6MC07

(3) Measurement
೵ Operate swing control lever fully.
೶ Swing 1 turn and measure time taken to
swing next 2 revolutions.
೷ Repeat steps ೵ and ೶ three time and
calculate the average values.
(4) Evaluation
The time required for 2 swings should meet the following specifications.
Unit : Seconds / 2 revolutions
Model Standard Maximum allowable Remarks
HX85A 12.6਺1.0 15.8

6-8
7) SWING FUNCTION DRIFT CHECK
(1) Measure the swing drift on the bearing
outer circumference when stopping after
a 360˚ full speed swing.
(2) Preparation
೵ Check the lubrication of the swing gear
and swing bearing.
೶ Place the machine on flat, solid ground
with ample space for swinging. Do not
conduct this test on slopes.
೷ With the arm rolled out and bucket rolled
in, hold the bucket so that the height of
the bucket pin is the same as the boom 85A6MC07
foot pin. The bucket must be empty.
೸ Make two chalk marks: one on the swing
bearing and one directly below it on the
track frame.
೹ Swing the upperstructure 360˚.
೺ Keep the hydraulic oil temperature at
50਺5˚C.
(3) Measurement
೵ Operate the swing control lever fully and
return it to the neutral position when the
mark on the upperstructure aligns with
that on track frame after swinging 360˚.
೶ Measure the distance between the two
marks.
೷ Align the marks again, swing 360˚, then
test the opposite direction.
೸ Repeat steps ೶ and ೷ three times each 85A6MC08

and calculate the average values.

(4) Evaluation
The measured drift angle should be within the following specifications.
Unit : Degree
Model Standard Maximum allowable Remarks
HX85A 90 below 127.6

6-9
8) SWING BEARING PLAY
(1) Measure the swing bearing play using a
dial gauge to check the wear of bearing
races and balls.
(2) Preparation
೵ Check swing bearing mounting cap
screws for loosening.
೶ Check the lubrication of the swing
bearing. Confirm that bearing rotation is
smooth and without noise.
೷ Install a dial gauge on the track frame as
shown, using a magnetic base.
೸ Position the upperstructure so that the 7-10(1) 140-7
boom aligns with the tracks facing
towards the front idlers.
೹ Position the dial gauge so that its needle
point comes into contact with the bottom
face of the bearing outer race.
೺ Bucket should be empty.
Measurement : h1
(3) Measurement
೵ With the arm rolled out and bucket rolled
in, hold the bottom face of the bucket to
the same height of the boom foot pin.
Record the dial gauge reading (h1).
೶ Lower the bucket to the ground and use 85A6MC09

it to raise the front idler 50 cm. Measurement : h2

Record the dial gauge reading (h2).
೷ Calculate bearing play (H) from this data
(h1 and h2) as follows.
H=h2-h1
85A6MC10
(4) Evaluation
The measured drift should be within the following specifications.
Unit : mm
Model Standard Maximum allowable Remarks
HX85A 0.5 ~ 1.5 3.0

6-10
9) HYDRAULIC CYLINDER CYCLE TIME
(1) Measure the cycle time of the boom,
standard arm, and standard bucket
cylinders.
(2) Preparation
೵ To measure the cycle time of the boom
cylinders:
With the arm rolled out and the empty
bucket rolled out, lower the bucket to the
ground, as shown.
೶ To measure the cycle time of the arm
cylinder.
With the empty bucket rolled in, position
the arm so that it is vertical to the ground.
Lower the boom until the bucket is 0.5m
above the ground.
೷ To measure the cycle time of the bucket
cylinder.
The empty bucket should be positioned
at midstroke between roll-in and roll-out,
so that the sideplate edges are vertical to
the ground.
೸ Keep the hydraulic oil temperature at
50਺5˚C.
85A6MC11
(3) Measurement
೵ To measure cylinder cycle times.
- Boom cylinders.
Measure the time it takes to raise the
boom, and the time it takes to lower the
boom. To do so, position the boom at
one stroke end then move the control
lever to the other stroke end as quickly
as possible.
- Arm cylinder.
Measure the time it takes to roll in the
arm, and the time it takes to roll out the
arm. To do so, position the bucket at
one stroke end, then move the control
lever to the other stroke end as quickly
as possible.

6-11
 - Bucket cylinders
Measure the time it takes to roll in the
bucket, and the time it takes to roll out
the bucket. To do so, position the bucket
at one stroke end, then move the control
lever to the other stroke end as quickly
as possible.
- Repeat each measurement 3 times and
calculate the average values.
(4) Evaluation
The average measured time should meet the following specifications.
Unit : Seconds

Model Function Standard Maximum allowable Remarks

Boom raise 3.0਺0.4 3.6
Boom lower 2.6਺0.4 3.1
Arm in 2.4਺0.4 2.9
Arm out 2.8਺0.3 3.4
HX85A
Bucket load 2.2਺0.4 2.6
Bucket dump 2.0਺0.3 2.4
Dozer up (raise) 3.5਺0.3 4.2
Dozer down (lower) 2.6਺0.3 3.1

6-12
10) DIG FUNCTION DRIFT CHECK
(1) Measure dig function drift, which can be
caused by oil leakage in the control valve
and boom, standard arm, and standard
bucket cylinders, with the loaded bucket.
When testing the dig function drift just
after cylinder replacement, slowly operate
each cylinder to its stroke end to purge air.
(2) Preparation
೵ Load bucket fully. Instead of loading the
bucket, weight (W) of the following
specification can be used.
ਠ W = M3਻1.5
Where :
M3 = Bucket heaped capacity (m3)
1.5 = Soil specific gravity
೶ Position the arm cylinder with the rod 20
to 30mm extended from the fully retracted 85A6MC12
position.
೷ Position the bucket cylinder with the rod
20 to 30mm retracted from the fully
extended position.
೸ With the arm rolled out and bucket rolled
in, hold the bucket so that the height of
the bucket pin is the same as the boom
foot pin.
೹ Keep the hydraulic oil temperature at
50਺5˚C.
(3) Measurement
೵ Stop the engine.
೶ Five minutes after the engine has been
stopped, measure the changes in the
positions of the boom, arm and bucket
cylinders.
೷ Repeat step ೶ three times and calculate
the average values.

(4) The measured drift should be within the following specifications.

Unit : mm / 5min

Model Drift to be measured Standard Maximum allowable Remarks

Boom cylinder 10 below 20
HX85A Arm cylinder 20 below 30
Bucket cylinder 40 below 50

6-13
11) C O N T R O L L E V E R O P E R AT I N G
FORCE
(1) Use a spring scale to measure the
maximum resistance of each control lever
at the middle of the grip.
(2) Preparation
೵ Keep the hydraulic oil temperature at
50਺5˚C.
(3) Measurement
೵ Start the engine.
೶ Operate each boom, arm, bucket and
swing lever at full stroke and measure
the maximum operating force for each.
೷ Lower the bucket to the ground to raise
one track off the ground. Operate the
travel lever at full stroke and measure
the maximum operating force required.
When finished, lower the track and then
jack-up the other track.
೸ Repeat steps ೶ and ೷ three times and
calculate the average values.
(4) Evaluation
The measured operating force should be within the following specifications.
Unit : kgf

Model Kind of lever Standard Maximum allowable Remarks

Boom lever 1.6 or below 2.0
Arm lever 1.6 or below 2.0
HX85A Bucket lever 1.6 or below 2.0
Swing lever 1.6 or below 2.0
Travel lever 2.1 or below 3.15

6-14
12) CONTROL LEVER STROKE
(1) Measure each lever stroke at the lever top
using a ruler.
੔ When the lever has play, take a half of this
value and add it to the measured stroke.
(2) Preparation
Keep the hydraulic oil temperature at
50਺5˚C.
(3) Measurement
೵ Stop the engine.
೶ Measure each lever stroke at the lever
top from neutral to the stroke end using a
ruler.
೷ Repeat step ೶ three times and calculate
the average values.
(4) Evaluation
The measured drift should be within the following specifications.
Unit : mm

Model Kind of lever Standard Maximum allowable Remarks

Boom lever 82਺10 103
Arm lever 82਺10 103
HX85A Bucket lever 82਺10 103
Swing lever 82਺10 103
Travel lever 148਺20 185

6-15
13) PILOT PRIMARY PRESSURE
(1) Preparation
೵ Stop the engine.
೶ Push the pressure release button to
bleed air.
೷ Loosen and remove plug on the pilot B1

pump delivery port (P2 ) and connect G B2

pressure gauge. Main pump

೸ Star t the engine and check for oil X

leakage from the port.

೹ Keep the hydraulic oil temperature at P1

50਺5˚C. G
P2
(2) Measurement
೵ Measure the primary pilot pressure in the 85A6MC13

M mode.
(3) Evaluation
The average measured pressure should meet the following specifications:
Unit : kgf / cm2

Model Standard Remarks

HX85A 31~34 at 1000rpm (Engine speed)

6-16
14) FOR TRAVEL SPEED SELECTING PRESSURE:
(1) Preparation Pressure
gauge
೵ Stop the engine.
೶ Push the pressure release button to
bleed air.
೷ To measure the speed selecting pressure:
Install a connector and pressure gauge
assembly to turning joint E port as shown. E

೸ Star t the engine and check for on

leakage from the adapter.
೹ Keep the hydraulic oil temperature at
50਺5˚C.
(2) Measurement
೵ Select the following switch positions.
Travel mode switch : 1 speed
2 speed
೶ Measure the travel speed selecting 80CR96MC14

pressure in the Hi or Lo mode.

೷ Lower the bucket to the ground to raise
the track off the ground. Operate the
travel lever at full stroke and measure
the fast speed pressure.
೸ Repeat steps ೶ and ೷ three times and
calculate the average values.
(3) Evaluation
The average measured pressure should be within the following specifications.
Unit : kgf / cm2

Model Travel speed mode Standard Maximum allowable Remarks

1 Speed 0 -
HX85A
2 Speed 33਺5 -

6-17
15) SWING PARKING BRAKE RELEASING PRESSURE
(1) Preparation
೵ Stop the engine.
೶ Push the pressure release button to
bleed air.
೷ Install a connector and pressure gauge PP
assembly to swing motor PP port, as B
shown. A
೸ Star t the engine and check for oil
leakage from the adapter. PB

೹ Keep the hydraulic oil temperature at

50਺5˚C.
(2) Measurement Swing motor
೵ Operate the swing function or arm roll in
function and measure the swing brake
c o n t r o l p r e s s u r e w i t h t h e b ra ke
disengaged. Release the control lever to 85A6MC15

return to neutral and measure the control

pressure when the brake is applied.
೶ Repeat three times and calculate the
average values.
(3) Evaluation
The average measured pressure should be within the following specifications.
Unit : kgf / cm2

Model Description Standard Remarks

Brake disengaged 25~40
HX85A
Brake applied 0

6-18
16) MAIN PUMP DELIVERY PRESSURE
(1) Preparation
೵ Stop the engine.
೶ Push the pressure release button to
bleed air.
೷ To measure the main pump pressure.
Install a connector and pressure gauge Main pump
B1

assembly main pump gauge port (B1) as

shown.
೸ Star t the engine and check for oil
leakage from the port. MCV S

೹ Keep the hydraulic oil temperature at

50਺5˚C.
(2) Measurement
೵ Measure the main pump deliver y
pressure at high idle.
Hyd tank 85A6MC17

(3) Evaluation
The average measured pressure should meet the following specifications.
Unit : kgf / cm2

Model Engine speed Standard Allowable limits Remarks

HX85A High idle 20਺5 -

6-19
17) SYSTEM PRESSURE REGULATOR RELIEF SETTING
(1) Preparation
೵ Stop the engine.
೶ Push the pressure release button to
bleed air.
೷ To measure the system relief pressure.
Install a connector and pressure gauge
assembly main pump gauge port, as
Main pump
shown. B1

೸ Star t the engine and check for oil

leakage from the port.
೹ Keep the hydraulic oil temperature at
50਺5˚C. MCV S

(2) Measurement
೵ Slowly operate each control lever of
boom, arm and bucket functions at full
stroke over relief and measure the
pressure.
Hyd tank
೶ In the swing function, place bucket 85A6MC17
against an immovable object and
measure the relief pressure.
೷ In the travel function, lock undercarriage
with an immovable object and measure
the relief pressure.
(3) Evaluation
The average measured pressure should be within the following specifications.
Unit : kgf / cm2

Model Function to be tested Standard Port relief setting

Boom, Arm, Bucket 285਺10 310਺10
HX85A Travel 285਺10 -
Swing 250਺10 -

6-20
GROUP 2 MAJOR COMPONENT

1. MAIN PUMP
Before inspection, wash the parts well and dry them completely.
Inspect the principal parts with care and replace them with new parts when any abnormal wear
exceeding the allowable limit or damage considered harmful is found.
Replace the seal also when any remarkable deformation and damage are found.

1) PISTON ASSEMBLY AND CYLINDER

BLOCK
(1) Check the appearance visually.
No damage, scouring, abnormal wear
(particularly, in the slide portion) should
be found. d D
(2) Check the clearance between the piston
outside dia and cylinder block inside dia.
D-d £ 0.050 mm

2) PISTON SHOE AND PISTON

(1) Check the axial play of the piston and
piston shoe.
儒 £ 0.2 mm

R55NM7PH46

3) SHAFT
(1) Check the wear amount of the oil seal
mounting section.
Wear mount £ 0.025 mm

R55NM7PH47

6-21
4) CONTROL PLATE
(1) Check the slide surface for any damage.
When the damage is large, replace the
plate with new one.

R55NM7PH48

5) GUIDE AND RETAINER

(1) Check for scouring or stepped wear.
If this can not be corrected, replace the
guide and retainer with new full-set.
(2) Fine scour ing or damage can be
corrected with lapping.
Carry out thorough washing after lapping.

R55NM7PH49

6-22
2. MAIN CONTROL VALVE

Part name Inspection item Criteria & measure

Block ·Existence of scratch, rusting or corrosion. ·In case of damage in following section, replace
part.
- Sliding sections of casing fore and spool,
especially land sections applied with holded
pressure.
- Seal pocket section where spool is inserted.
- Seal section of port where O-ring contacts.
- Seal section of each relief valve for main,
travel, and port.
- Other damages that may damage normal
functions.
Spool ·Existence of scratch, gnawing, rusting or ·Replacement when its outside sliding section
corrosion. has scratch (especially on seals-contacting
section).
·O-ring seal sections at both ends. ·Replacement when its sliding section has
scratch.
·Insert spool in casing hole, rotate and ·Correction or replacement when O-ring is
reciprocate it. damaged or when spool does not move
smoothly.
Poppet ·Damage of poppet or spring ·Correction or replacement when sealing is
incomplete.
·Insert poppet into casing and function it. ·Normal when it can function lightly without
being caught.
Around spring ·Rusting, corrosion, deformation or breaking of ·Replacement for significant damage.
spring, spring seat, plug or cover.
Around seal ·External oil leakage. ·Correction or replacement.
for spool
·Rusting, corrosion or deformation of seal plate. ·Correction or replacement.
Main relief valve & ·External rusting or damage. ·Replacement.
port relief valve
·Contacting face of valve seat. ·Replacement when damaged.
·Contacting face of poppet. ·Replacement when damaged.
·Abnormal spring. ·Replacement.
·O-rings, back up rings and seals. ·100% replacement in general.

6-23
3. SWING MOTOR
1) POSSIBLE REASONS FOR THE TROUBLE AND ITS COUNTERMEASURES

Trouble Possible reasons Countermeasure

Setting pressure is too low. Replace the relif valve

Relief valve
Faulty operation. assembly.

Motor does not move. Burned inner parts. Replace the hydraulic motor
The supplied pressure is Hydraulic motor
Too much internal leakage. assembly.
enough.
Replace the reduction gear
Reduction gear Damage to the gears.
assembly.
Overload - Remove the overload.
Setting pressure is too low. Replace the relief valve
Relief valve
Faulty operation. assembly.

Burned sliding parts. Replace the hydraulic motor

Insufficient torque Hydraulic motor
Too much internal leakage. assembly.

Damage to the gears. Replace the pinion kit, carrier

Reduction gear
Damage to bearings. kit.

Cavitation noise Insufficient flow. Adjust the piping.

Replace the hydraulic motor
Hydraulic motor Damage to sliding parts.
assembly.
Abnormal noise
Damage to the gears. Replace the pinion kit, carrier
Reduction gear
Damage to bearings kit.

Pinion gear Damage to the gear surface. Replace the pinion kit.
Damage to O-rings. Replace the O-ring
Body gasket
Oil leakage Loose bolts. Re-tighten the loose bolts.
Pinion gear Damage to oil seal. Replace the pinion kit.
Replace the relief valve
Delay in start up, or delay Relief valve Faulty operation.
assembly.
in stopping
Check valve Internal leakage. Replace the body H kit.
Burned or damaged sliding Replace the hydraulic motor
Hydraulic motor
parts. assembly.
Excessive heat generation
Damage to the gears. Replace the pinion kit, carrier
Reduction gear
Damage to bearings kit.

6-24
 2) STANDARD FOR PARTS INSPECTION
(1) Reduction gear section

Part Extent of the damage Inspection standard Action

Pitching
Excessive wear of the Pitching area 5% or more of Replace the pinion kit.
A internal gear surface the gear surface

Carrier 1 Damage to spline By visual Replace the carrier kit.

Carrier 2 section
Pitching
Excessive wear of the Pitching area 5% or more of Replace the carrier kit.
surface the gear surface
S1 gear
S2 gear
b1 gear Excessive wear of the By visual pitching, flaking
b2 gear bearing surface

Excessive wear of the By visual pitching, flaking Replace the carrier kit.
Ring bearing surface

Excessive wear of the By visual pitching, flaking Replace the carrier kit.
Roller bearing surface

Other (O-ring, Damage, excessive Replace each part.

rust -
screw, etc.)

(2) Hydraulic motor section

Part Extent of the damage Inspection standard Action

Excessive wear of the Worn depth : 25儙m or more Replace the hydraulic
Shaft spline section motor assembly.

Excessive wear to the Worn depth : 20儙m or more Replace the cylinder
Cylinder barrel sliding surface of the barrel kit.
valve plate
Excessive wear to the Worn depth : 20儙m or more Replace the cylinder
Valve plate sliding surface of the barrel kit.
cylinder barrel
Wear of joint section of Play of piston and shoe : 0.3 mm or more by Replace the cylinder
Piston shoe shoe hand operation barrel kit.

Excessive wear to the Worn depth : 0.1 mm or more Replace the swash
Swash plate sliding surface of the plate kit.
shoe
Damage, excessive Replace each part.
Other (O-ring,
rust -
screw, etc.)

6-25
4. TRAVEL DEVICE
Maximum
Standard allowable value
Part name Check point dimension Remedy
(criteria)
Piston assy (13) Play between piston = 0.1 mm < 0.5 mm Replace 9 sets of
and slipper piston assy

P i s t o n a s s y ( B ) a n d Clearance/diameter 0.03 mm < 0.07 mm Replace the set of

cylinder block (8) between piston diamet- 1 cylinder barrel
er and cylinder bore and 9 piston assys
(儑1 +儑2)
儑1
儑2

Slipper Height of the plate Height H Height Replace 9 sets of

5 mm H < 4.6 mm piston assy
H

Retainer (11) Wear Wear depth Replace

< 0.2mm
儑

Swash plate (7) Condition of sliding Roughness Roughness Replace

surface < Ra 0.2µm < Ra 1.6µm

6-26
 Maximum
Standard allowable value
Part name Check point dimension Remedy
(criteria)
Shaft (3) Spline sections (con- - No abnormality Replace
nected to cylinder such as crack,
barrel, and bear part) chipping, nonuni-
formly wear-ing
out, etc.

Bearings (4), (45), (63), Rolling surface - N o f l a k i n g o r Replace

(72) other abnormal
damage on the
rolling surf-ace
Oil seal (2) Seal lip - N o d a m a g e o r Replace
partial wear
O-rings, - - - In reassembling,
Back-up rings they should be
replaced with new
ones even if no
abnormality is det-
ected.
Cylinder block (8) Condition of the surface Roughness Roughness Replace the set of
sliding with valve plate < Ra 0.2µm < Ra 0.8µm cylinder barrel and
valve plate
Valve plate (12) Condition of sliding sur- Roughness Roughness Replace the set of
face < Ra 0.4µm < Ra 1.6µm cyli-nder barrel and
valve plate

6-27
5. TURNING JOINT
Part name Maintenance standards Remedy
Body, Sliding surface with Plating worn or peeled due to seizure or contamination. Replace
Stem sealing sections.

Sliding surface ·Worn abnormality or damaged more than 0.1 mm Replace

between body and (0.0039 in) in depth due to seizure contamination.
stem other than
sealing section. ·Damaged more than 0.1 mm (0.0039 in) in depth. Smooth with oilstone.

Sliding surface with ·Worn more than 0.5 mm (0.02 in) or abnormality. Replace
thrust plate.
·Worn less than 0.5 mm (0.02 in). Smooth
·Damage due to seizure or contamination remediable Smooth
within wear limit (0.5 mm) (0.02 in).
Cover Sliding surface with ·Worn more than 0.5 mm (0.02 in) or abnormality. Replace
thrust plate.
·Worn less than 0.5 mm (0.02 in). Smooth
·Damage due to seizure or contamination remediable Replace
within wear limit (0.5 mm) (0.02 in).

Seal set ·Extruded excessively from seal groove square ring. Replace

- Extrusion
Square ring

·Slipper ring 1.5 mm (0.059 in) narrower than seal Replace

groove, or narrower than back ring.

1.5 mm (max.)
(0.059 in)

·Worn more than 0.5 mm (0.02 in) ~ 1.5 mm (MAX.) Replace

(0.059 in)

6-28
6. CYLINDER
Part name Inspecting section Inspection item Remedy
Piston rod ·Neck of rod pin ·Presence of crack ·Replace
·Weld on rod hub ·Presence of crack ·Replace
·Stepped part to which piston ·Presence of crack ·Replace
is attached.
·Threads ·Presence of crack ·Recondition or replace
·Plated surface ·Plating is not worn off to ·Replace or replate
base metal.
·Rust is not present on plating. ·Replace or replate
·Scratches are not present. ·Recondition, replate or
replace
·Rod ·Wear of O.D. ·Recondition, replate or
replace
·Bushing at mounting part ·Wear of I.D. ·Replace
Cylinder tube ·Weld on bottom ·Presence of crack ·Replace
·Weld on head ·Presence of crack ·Replace
·Weld on hub ·Presence of crack ·Replace
·Tube interior ·Presence of faults ·Replace if oil leak is seen
·Bushing at mounting part ·Wear on inner surface ·Replace
Gland ·Bushing ·Flaw on inner surface ·Replace if flaw is deeper
than coating

6-29
GROUP 3 TRACK AND WORK EQUIPMENT

1. STEEL TRACK
1) TRACK ROLLER

80CR96MC21

Unit : mm

No. Check item Criteria Remedy

Standard size Repair limit
1 Outside diameter of flange
Ø149 -
Rebuild or
2 Outside diameter of tread Ø125 Ø115
replace
3 Width of tread 35 40
4 Width of flange 13 -
Standard size & tolerance Standard Clearance
Clearance between shaft Shaft Hole clearance limit Replace
5
and bushing bushing
0 +0.3 0.25
Ø40 -0.03 Ø40 2.0
+0.25 to 0.33

Side clearance of roller Standard clearance Clearance limit

6 Replace
(both side) 0.4~1.21 2.0

6-30
2) CARRIER ROLLER

80CR96MC20

Unit : mm

No. Check item Criteria Remedy

Standard size Repair limit
1 Outside diameter of flange
Ø115 -
Rebuild or
2 Outside diameter of tread Ø95 Ø85
replace
3 Width of tread 31 35
4 Width of flange 11 -
Standard size & Tolerance Standard Clearance
Clearance between shaft Shaft Bushing clearance limit
5
and bushing
0 +0.35 0.3 Replace
Ø38 -0.03 Ø38 2.0
+0.3 ~ 0.38 bushing
or shaft
Shaft Support
Clearance between shaft 0.3
6 1.2
Ø38 -0.2
and support +0.3 ~ 0.6
Ø38
-0.3 +0.1

6-31
3) IDLER

8
1
2

7
3 5
4

85A7MS03

Unit : mm

No. Check item Criteria Remedy

Standard size Repair limit
1 Outside diameter of protrusion
Ø440 -
2 Outside diameter of tread Ø410 Ø400 Rebuild or
3 Width of protrusion 40 - replace

4 Total width 100 -

5 Width of tread 30 35
Standard size & Tolerance Standard Clearance
Clearance between shaft Shaft Bushing clearance limit Replace
6
and bushing bushing
0
Ø60 -0.03 Ø60.3 +0.08 0.33~0.41 2.0
+0.03
Clearance between shaft 0 +0.07
7 Ø60 -0.03 Ø60 0.03~0.1 1.2 Replace
and support +0.03

Side clearance of idler Standard clearance Clearance limit Replace

8
(both side) 0.2~0.5 2.0 bushing

6-32
4) TRACK
(1) Steel track

2 1

4
3

21037MS04

Unit : mm
No. Check item Criteria Remedy
Standard size Repair limit Turn or
1 Link pitch
154 158.3 replace

2 Outside diameter of bushing Ø41.3 Ø34.3

Rebuild or
3 Height of grouser 20 10 replace
4 Height of link 74 66
5 Tightening torque Initial tightening torque : 25.5±2.5 kgf·m Retighten

6-33
(2) Rubber track

1
B

A
B SECTION B-B
A
3
2

SECTION A-A
R5576MC17

Unit : mm
Criteria
No. Check item Remedy
Standard size Tolerance Repair limit
1 Link pitch 83.5 佳1.0 87
2 Height of grouser 30 - 5 Replace
3 Width of link 52 - 70

6-34
5) TRACK FRAME AND RECOIL SPRING

3
1

7077MS20

Unit : mm

No. Check item Criteria Remedy

Standard size Tolerance Repair limit
+2
Track frame 92 96
1 Vertical width of idler guide 0
-0 Rebuild or
Idler support 90 87
-1.5 replace
+2
Track frame 172 176
2 Horizontal width of idler guide 0
Idler support 170 - 168
Standard size Repair limit
Free Installation Installation Free Installation
3 Recoil spring Replace
length length load length load
Ø170佴360 320 4,816 kg - 3,955 kg

6-35
2. WORK EQUIPMENT

F E D C B A

G H I J K N L O M

85A6MC22

Unit : mm
Pin Bushing
Remedy
Measuring point Normal Recomm. Recomm.
Mark Limit Limit &
(Pin and Bushing) value service service
of use of use Remark
limit limit
A Boom rear 65 64 63.5 65.5 66 Replace
B Boom cylinder head 65 64 63.5 65.5 66 佝
C Boom cylinder rod 65 64 63.5 65.5 66 佝
D Arm cylinder head 65 64 63.5 65.5 66 佝
E Boom front 65 64 63.5 65.5 66 佝
F Arm cylinder rod 65 64 63.5 65.5 66 佝
G Bucket cylinder head 50 49 48.5 50.5 51 佝
H Arm link 55 54 53.5 55.5 56 佝
I Bucket and arm link 55 54 53.5 55.5 56 佝
J Bucket cylinder rod 55 54 53.5 55.5 56 佝
K Bucket link 55 54 53.5 55.5 56 佝
L Boom swing post 110 109 108.5 110.5 111 佝
M Boom swing cylinder 65 64 63.5 65.5 66 佝
N Blade cylinder 65 64 63.5 65.5 66 佝
O Blade and frame link 55 54 53.5 55.5 56 佝

6-36